(9) Use valve key to remove discharge valve assembly (l6). Discharge valve assembly (16) is not reusable and must
Remove cylinder (17) and gasket (18).
Carefully rotate crankshaft by hand so that the piston pin (19) of piston (20) is above the level of the crankcase.
Remove two snap rings (21).
Remove the piston pin (19) and remove piston (20).
Using a piston ring expander, remove piston rings (22). If necessary, remove studs (23).
Provide adequate ventilation when using cleaning solvent. Avoid prolonged breath-
ing of vapors and minimize skin contact. Solvent is highly flammable. Keep away
from sources of heat and open flame.
Do not use more than 30 psig (207 kPa) compressed air for parts cleaning. Keep other
workers at a safe distance when cleaning parts with compressed air.
a. Clean all parts in solvent and blow dry with compressed air 30 psig (207 kPa) maximum.
b. Inspect pistons for scratches, broken areas between rings and general damage. Replace as necessary.
c. Inspect cylinders for internal scratches that could cause leaks, and broken exterior fins. Replace as necessary.
The piston and sleeve must be replaced as a set.
d. Check piston and sleeve assembly (20, Figure 2-82) for excessive wear or deep scratches. Replace as necessary.
e. Inspect heads and valves for pitting and corrosion. Corrosion in or around valve ports is cause for replacement.
f. Inspect intercooler and aftercooler tubes for damage and evidence of leaks. Replace as necessary.
g. Inspect all threaded connectors for damage or stripped threads. Replace parts as necessary.
h. Inspect drive belts for cuts or cracking. Replace worn or damaged belts.
i. Inspect rubber grommets and mounting pads for distortion or deterioration. Replace as necessary.
j. Refer to Table 3-1. Replace any component(s) exceeding clearance or tolerance limits.
a. Assemble First Stage Components:
Slotted ring goes in bottom groove. Ring with machined shoulder around diameter
goes in middle groove (with shoulder facing bottom of piston). Solid ring goes in top
Be sure that TOP mark on piston rings is facing upwards and that gaps in piston rings
are not directly above piston pins. Gaps in adjacent rings must be at least 90° apart.
(1) Use piston ring expander to install piston rings (22, Figure 2-82) on piston (20).
(2) Compress rings (22) and install piston (20) into cylinder (17), allowing clearance to install piston pin (19).
(3) Install studs (23) and position new gasket (18) on crankcase.